Sole Coated Toe Sock

ABSTRACT

The present invention relates to socks and related items and specifically, toe socks that are breathable but include a thin protective barrier on the sole to guard against most types of penetration. The invention comprises a five toed sock that includes a thin elastomer protective layer, preferably natural latex rubber or nitrile, generally located on the exterior portions of the heel, arch, pad, and toes sections.

A. CROSS-REFERENCE TO RELATED APPLICATIONS

None.

B. GOVERNMENT SUPPORT

None.

C. REFERENCE TO SEQUENCE LISTING, TABLE, ETC

Not Applicable.

D. BACKGROUND OF THE INVENTION

The present invention relates to socks and related items and specifically, toe socks that are breathable but include a thin protective barrier on the sole to guard against most types of penetration.

There is a growing movement afoot to study the potential harm done by running shoes. Proponents of barefoot running claim that it causes less collision force to the feet than running in cushioned shoes, and that runners who run without shoes usually land on the balls of their feet (forefoot strike), or sometimes flat-footed (midfoot strike), compared to runners in shoes, who tend to land on their heels first (heel strike).

Proponents of barefoot running believe that cushioned running shoes, which date back to the 1970s, may seem comfortable but may actually contribute to a variety of injuries, including foot, ankle, knee, and hip injuries. By running on the midfoot, or preferably the forefoot, runners may avoid more forceful impacts, equivalent to two to three times of body weight, which shod heel-strikers repeatedly experience. By landing on the middle or front of the foot, barefoot runners have much less impact collision than most shod runners generate when they heel-strike.

Barefoot runners tend to point their toes more at landing, reducing the collision effect. Modern running shoes are designed to make heel-striking easy and comfortable, while running shoeless forces the athlete to run in a more ergonomic way, land on their forefoot, and use shorter strides. That puts less stress on sensitive joints.

Further, there are many other beneficial aspects of barefoot running, including: helping to develop better perception of the contact with the ground, which allows the athlete to land with support more efficiently; placing the body weight on the foot more precisely; and having better timing with the contact with the ground. Exercising barefoot also develops muscle strength, particularly in those groups of muscles of the feet, and related muscles of the legs and hips, much more than when we are in shoes.

Proponents of barefoot running also argue that it is healthier for feet and reduces risk of chronic injuries, notably repetitive stress injuries due to the impact of heel striking in padded running shoes, in addition to other purported benefits. Modern running shoes are typically characterized by thick padded soles, generally wedge-shaped with more padding at the heel and less at the forefoot, and, stiff, supportive insoles, which produce an unnatural gait. Following the evolution of the human foot, human running was universally barefoot or in thin-soled shoes such as moccasins, which continues to this day in some parts of the world, such as Kenya. Many runners have switched to barefoot running for relief from chronic injuries. The structure of the foot and lower leg is very efficient at absorbing the shock of landing and turning the energy of the fall into forward motion, through the springing action of the foot's natural arch. It is only by placing large amounts of padding under the heel that humans are able to land on the heel rather than the ball of the foot. In doing so, the foot's natural motion is impeded and the arch and lower leg are not able to absorb the shock of the landing. Instead, the shock is sent up through the heel, to the knees and hips.

Proponents also argue that running barefoot is associated with a substantially lower prevalence of acute injuries of the ankle and chronic injuries of the lower leg in developing countries. Running in shoes may increase the risk of ankle sprains, either by decreasing awareness of foot position or by increasing the twisting torque on the ankle during a stumble. Running shoes may also increase the risk of plantar fasciitis and other chronic injuries of the lower limb by modifying the transfer of shock to muscles and supporting structures.

Benefits accrue when performing other activities without shoes as well, including but not limited to walking, hiking, and weight lifting. For instance weight lifting performed in shoes often puts the person into bad posture or incorrect form, since the elevated heels cause postural compensation. The elevated heel typically causes the person to lean forward, which then causes the person to lean back to compensate. This puts an unnatural curve in their spine and can cause injury.

However, exercising while barefoot has the potential to cause problems as a result of the activity. This includes the fact they provide no protection from outside elements. When a person is barefoot outside, their feet can be exposed to wet, cold and windy conditions with no insulation or protective barrier.

Further, when performing athletic activities barefoot, toughened, callused areas of skin develop on the bottom of the feet. The soles of the feet become relatively thick and hard in response to repeated friction, pressure or other irritation. Over time the thick layers of skin will start to form on different areas of the foot that constantly make contact with the ground. When the calluses form it may cause the athlete's feet to peel, crack, and become rough, and look unpleasant. To build up calluses, a person would have to start slowly by running or walking short distances. This would limit the person's duration of activities for an extended period of time until they thicken the skin on the sole of their feet. The bottoms and sides of the person's feet would also start to turn black with repeated contact on dirty surfaces. The overall cleanliness of the person's feet is dramatically impacted when no protection is worn.

Another negative consequence of barefoot running is that constant contact with hard ground and rough surfaces, particularly prior to developing calluses, can cause lacerations, abrasion burns, blisters and bleeding. This is especially true when running barefoot on harder surfaces, such as cement and pavement. Further, there are many natural and manmade objects found on the ground today that make it unsafe to walk or run on bare feet. Things such as jagged rocks, thorns, sharp twigs, glass, metals, plastics and other debris found in urban areas are a major concern to a barefoot runner. Hazardous materials in liquid or powder form could also penetrate bare skin with no layer of protection. Lastly, if a person is barefoot, he or she cannot typically work out at fitness facilities, walk into most stores or attend certain social events. It is sometimes frowned upon socially to be barefoot in public.

Previous attempts to reduce the problems associated with running shoes have included Injinji (U.S. Pat. No. 7,069,600 and U.S. Pat. No. 6,708,348) which claims its products simulate barefoot running when worn in traditional running shoes. However, most proponents of barefoot running claim that a foot cannot function naturally inside of a shoe due to the fact that it is constricted by the lacing system, elevated on a thick sole cushion, and is influenced to strike heel first. The feet and leg muscles in such a situation are still restricted in their development just as they would be when wearing a normal sock in a traditional shoe.

Further, the Injinji socks may provide insufficient protection when worn alone, since they do not offer adequate protection from the grounds surface or sharp objects. They are specifically made to be worn in shoes because the fabric on the bottom of the socks cannot hold up after prolonged contact with the ground.

Other attempts to simulate barefoot running include products such as Vibram Fivefingers. However these products include a sole insert and a thick rubber bottom layer. These two layers (three if socks are also worn) create a sole thickness that is too thick to properly simulate barefoot running, and negatively affect the user's balance, posture, and running style. Further negatives for these products include extra weight, and lack of washability, as well as providing artificial arch support which hinders the foot's arch from performing its natural function of acting as a spring to propel the body forward. An arch support restricts the muscles, tendons and ligaments from developing to their full potential.

Various types of socks that provide protection are known in the prior art. One group of socks includes socks made to be worn with a shoe. These socks are typically made of cotton, wool or synthetic fibers, and/or blends thereof. Another group of known socks includes socks made to be worn without a shoe. Some of these socks have a coating that resists moisture penetration, and protects the foot from injury by sharp objects, permitting the sock to be worn outside of the house. However, these socks do not allow for toe separation, which is critical to simulate barefoot running.

There are numerous socks and sock-like items that can protect the foot from dirt, but are described in the prior art as having a hard and durable exterior coating and are presented as a substitute for a shoe. Examples include U.S. Pat. No. 5,617,585 issued to Fons et al, for a rubber-soled slipper sock, and U.S. Pat. Nos. 4,276,671, 3,383,782 and 266,614. The expressed intent of all these inventions is to protect the foot. The most common means for achieving this goal is coating the sock with a thick substance, typically resin, rubber or a rubber-like derivative such as latex. All of these inventions state that their socks can be worn in shoes. Also, by virtue of the chemical properties of the coating agents, they are typically not air permeable, and therefore may interrupt the normal respiration/transpiration of the epidermal cells of the foot. Furthermore, these products are typically not washable.

The prior art also includes sock-like items that attempt to address the problem of drying and cracking of the skin of the foot. These items allow for the use of an emollient while a sock-like item is being worn. There is no recommendation that they be worn with shoes outdoors, and none address the issue of preventing the penetration of dirt through the sock.

Therefore, there is a need for a way to enjoy the benefits of barefoot running and other sports, while eliminating the negative consequences. A need exists for a sock that provides comfort, protection, tensile strength, and the durability to withstand washing, yet resists dirt and other debris from penetrating into and/or through the sock material.

E. BRIEF SUMMARY OF THE INVENTION

The invention comprises a five toed sock that includes a thin elastomer protective layer, preferably natural latex rubber or nitrile, on the bottom surfaces (sole). When socks have compartments for individual toes, the toes can move more freely than in a traditional sock. The feeling is much more akin to being barefoot.

A toe sock allows the entire foot to perform naturally, encouraging the toes to separate and activate the muscles in the feet. Toe socks increase dexterity and tactile sensitivity and awareness during any activity. Toe socks help to strengthen the muscles in the feet, while allowing for overall better circulation, balance and posture.

The five toe design reduces friction between toes and minimizes moisture around the foot. Reduced movement in your socks means less chance of developing blisters while you exercise. Accordingly, it is the object of the present invention to provide a sock that resists movement of dirt or other debris from the outside inward.

It is yet another object of the present invention to provide a sock that is coated with a protective layer on the sole, the protective elastomer layer, preferably being natural rubber or nitrile or a like substance.

It is an object of the present invention to provide a sock that has the properties that allow it to be laundered.

These and related objects of the present invention are achieved by use of a rubber or nitrile coated sock as described herein.

The attainment of the foregoing and related advantages and features of the invention should be more readily apparent to those skilled in the art, after review of the following more detailed description of the invention taken together with the drawings.

F. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the invention.

FIG. 2 is a side view of the invention.

FIG. 3 is a rear view of the heel area of the invention.

FIG. 4 is a top view of the invention.

FIG. 5 is a bottom exterior view of the invention.

FIG. 6 is a cross sectional view of the invention.

G. DETAILED DESCRIPTION OF INVENTION

Referring to FIG. 1, a sectional view of the invention is shown that includes a sock material 3 that may be formed in whole or part of any suitable material, such as nylon, polypropylene, and others. This sock material 3 will be in direct contact with the skin of the user. In one embodiment, the sock material 3 comprises polyester, acrylic, and/or nylon, as these materials have moisture wicking properties suitable for athletic activities. A shaft support section 1 is shown directly above and encircling the ankle that contains an additional amount of elastic to maintain the position of the sock on the wearer.

The elastomer coating 4 is shown on the exterior bottom surfaces of the sock, and extends slightly up the back and sides of the sock. The elastomer coating 4 is a polymer with the property of viscoelasticity (colloquially “elasticity”), generally having notably low Young's modulus and high yield strain compared with other materials. The term, which is derived from elastic polymer, is sometimes used interchangeably with the term rubber. Each of the monomers which link to form the polymer is usually made of carbon, hydrogen, oxygen and/or silicon. Elastomers are amorphous polymers that allow for considerable segmental motion. At ambient temperatures rubbers are thus relatively soft (E˜3 MPa) and deformable.

Examples of elastomers include unsaturated rubbers that can be cured by sulfur vulcanization: Natural rubber (NR); Synthetic polyisoprene (IR); Butyl rubber (copolymer of isobutylene and isoprene, IIR); Halogenated butyl rubbers (chloro butyl rubber: CIIR; bromo butyl rubber: BIIR); Polybutadiene (BR); Styrene-butadiene Rubber (copolymer of polystyrene and polybutadiene, SBR); Nitrile rubber (copolymer of polybutadiene and acrylonitrile, NBR), also called Buna N rubbers; Hydrogenated Nitrile Rubbers (HNBR) Therban and Zetpol; Chloroprene rubber (CR), polychloroprene, Neoprene, and Baypren etc.

Elastomers may also include saturated rubbers that cannot be cured by sulfur vulcanization include EPM (ethylene propylene rubber, a copolymer of ethylene and propylene) and EPDM rubber (ethylene propylene diene rubber, a terpolymer of ethylene, propylene and a diene-component); Epichlorohydrin rubber (ECO); Polyacrylic rubber (ACM, ABR); Silicone rubber (SI, Q, VMQ); Fluorosilicone Rubber (FVMQ); Fluoroelastomers (FKM, and FEPM) Viton, Tecnoflon, Fluorel, Aflas and Dai-El; Perfluoroelastomers (FFKM) Tecnoflon PFR, Kalrez, Chemraz, Perlast; Polyether block amides (PEBA); Chlorosulfonated polyethylene (CSM), (Hypalon); and Ethylene-vinyl acetate (EVA).

Various other types of elastomers include: Thermoplastic elastomers (TPE), for example Elastron, etc.; Thermoplastic vulcanizates (TPV), for example Santoprene TPV; Thermoplastic polyurethane (TPU); Thermoplastic olefins (TPO); the proteins resilin and elastin; and polysulfide rubber.

The protective elastomer coating 4 on the sole (including the exterior portions of the heel 6, arch 8, pad 10, and toe 12 sections, enumerated in FIG. 6) is preferably very thin. Ideally, the minimum thickness of the protective coating layer should be sufficient to withstand repeated contact with ground surfaces. This minimum thickness may depend on the particular material used, however will probably be in the range of 0.1 mm to 1.0 mm. The layer of protective coating preferably does not exceed 4 mm. Thickness exceeding this depth may tend to provide a sufficient cushion to encourage unwanted heel strikes. As such, the optimal thickness of the protective coating is approximately 0.5 millimeters to 4 millimeters.

Nitrile butadiene rubber (NBR) is a family of unsaturated copolymers of 2-propenenitrile and various butadiene monomers (1, 2-butadiene and 1, 3-butadiene). Although its physical and chemical properties vary depending on the polymer's composition of nitrile, this form of synthetic rubber is generally resistant to oil, fuel, and other chemicals (the more nitrile within the polymer, the higher the resistance to oils but the lower the flexibility of the material).

Nitrile rubber is more resistant than natural rubber to oils and acids, but has less strength and flexibility. For those allergic to natural rubber, nitrile can be a suitable substitute. It is a synthetic polymer that exhibits rubber-like properties when vulcanized. The polymer is made in the form of a latex emulsion, and in latex form can be processed much like natural rubber latex. Compared to natural rubber latex, however, which is a polyisoprene, nitrile is typically composed of three monomers: acrylonitrile, butadiene and carboxylic acid. After vulcanization, the butadiene component contributes to softness and flexibility, while the carboxylic acid provides high tensile strength and tear resistance. In addition, nitrile coating has been shown to withstand cleaning, including conventional laundering, while retaining its desired properties. Nitrile has also proven to be air permeable.

Although a variety of materials could be used as the protective coating, natural rubber is ideally suited to be used as the protective layer on the sole. Natural rubber has certain advantages over other materials, including a greater level of resistance to abrasions, punctures, cuts, and water. Natural rubber can be laundered, and can be textured for additional abrasion resistance and grip.

In FIG. 2, the protective elastomer coating 4 extends up and around the exterior of the heel section 6 by approximately 2 inches, forming a cup around the heel. The sock shaft section 14 (enumerated in FIG. 6) includes a shaft support section 1 to encircle a lower part of a leg of a wearer and maintain the sock in proper orientation upon the leg. The thickness of the elastomer coating 4 may vary at different locations on the sock. The sock could also be ‘double dipped’ in the elastomer coating during the manufacturing process.

FIG. 3 shows a rear view of the sock with the protective elastomer coating extending approximately 1 to 2 inches up and around the heel section 6 to form a cup surrounding the heel.

FIG. 4 shows a top down view wherein the sock opening 16 is shown with the shaft support section 1 that comprises an elastic material to maintain the position of the sock on the lower leg of the wearer. The protective elastomer coating may also be located on the sides of the sock to create additional protection to the foot, but since only the sock material 3 is present on most of the top portions of the sock, the sock remains breathable and does not promote excess heat retention or sweating.

A shaft support section 1 is shown directly above and encircling the ankle that contains an additional amount of elastic. In one embodiment, the elastomer coating is applied to the sole and heel and extends at least ¾ of an inch up the sides of the shaft. It should be recognized that the elastomer may extend above or below this level or be otherwise configured. The elastomer coating is preferably odorless, non-toxic and hypoallergenic, and substantially liquid impermeable.

The five individual toe cavities 12 (together referred to as the ‘toes section’) are configured to receive, retain, and allow independent articulation of corresponding individual toes of a foot inserted in the footwear. Each toe cavity will have an interior and an exterior top side and under side, wherein the interior top and undersides will present sock material 3, such that the wearer's toes come into contact with the sock material 3 during use. The external underside of the toe cavities will present the elastomer coating 4. The exterior of the top side of the toe cavities 12 may include the elastomer coating 4.

In FIG. 5, the protective elastomer coating 4 is shown covering the entirety of the sole. A section of the protective elastomer coating 4 is magnified in order to show that the coating can be made with a pattern. The patterns on the coating can vary widely, and are not limited to the pattern shown in this figure. The patterning can be functional, in that certain patterns may tend to provide better traction for certain activities. The color and texture of the elastomer coating 4 can also be varied.

FIG. 6 shows a cross section of the invention, including the sock material 3 located on the interior of the sock, the protective elastomer coating 4, a shaft section 14, a heel section 6, an arch section 8, a pad section 10 (generally located at the metatarsal area of the foot, or the balls of the foot), and the toe section 12. Since FIG. 6 shows a cross section of the sock, it does not show the toes sections 12 as being separated. However, the toes section 12 comprises five toe cavities configured to receive, retain, and allow independent articulation of the corresponding individual toes of a foot inserted into the footwear. Each toe cavity has a top side and an under side, and the toe cavities are separated by trough regions that keep the toes separate.

An aspect of the invention involves a toe sock shaped to fit either a right foot or a left foot of a wearer. The toe sock includes a sock shaft section 14 including an open end 16 (see FIG. 4) through which the foot of the wearer is inserted when the sock is put on. A closed foot section is adapted to receive the foot of the wearer and includes a heel section 6, an arch section 8, and five separated, closed toe sections 12 to receive the toes of the foot of the wearer.

The size of the shaft 14, or area of the sock above the foot, may vary widely, from ankle height to knee height, or other. The present invention includes socks of any size, though in one embodiment, a shaft 14 is provided that extends approximately 3 inches above the ankle The shaft may include a portion provided above the ankle that is ribbed and elasticized.

While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modification, and this application is intended to cover any variations, uses, or adaptations of the invention and including departures from the present disclosure as come within known or customary practice in the art to which the invention pertains and as may be applied to the essential features herein set forth, and as fall within the scope of the invention and the limits of the appended claim. 

1. A sock, said sock comprising: a. An interior and an exterior shaft, heel, arch, pad, and toes section; b. Wherein the shaft section includes an open end through which the foot of the wearer is inserted when the sock is put on, the sock shaft section including a shaft support section to encircle a lower part of a leg or ankle of a wearer and to maintain the sock in proper orientation upon the leg or ankle; the closed foot section adapted to receive the foot of the wearer, and includes the heel, arch, pad, and toe sections; c. the toes section comprising: i. five individual toe cavities configured to receive, retain, and allow independent articulation of corresponding individual toes of a foot inserted in the footwear; ii. each toe cavity comprising a top side and an under side; and iii. at least one layer of elastomer coating generally located on the exterior portions of the heel, arch, pad, and toe sections.
 2. The sock of claim 1, wherein the elastomer protective coating is formed from one or more selected from a group consisting of: a. Natural rubber; b. Nitrile.
 3. The sock of claim 1, wherein the sock is shaped to fit either a right foot or a left foot.
 4. The sock of claim 1, wherein the interior shaft, heel, arch, pad, and toes sections are formed from one or more selected from a group consisting of: a. Nylon; b. Wool; c. Acrylic; and d. Polyester.
 5. The sock of claim 1, wherein the elastomer layer has a thickness of approximately 0.5 millimeters to approximately 4 millimeters.
 6. The sock of claim 1, wherein a pattern is incorporated into the elastomer coating. 